Synthesis gas- manufacture



Patented July 29, 1952 SYNTHESIS GAs- MANUFACTURE 'Joseph o. Krejcrriliuips, Tex., assigner to Phillips Petroleum Company,

Delaware a corporation of Application January 4, 1949, serial No. 69,1714

(c1. @ls-196) lll Claims.

1 l l This inventionrelates to the manufacture of synthesis gas. In one aspect this invention relates to the production of hydrocarbons and oxygen derivatives of hydrocarbons. In another aspect this invention relates to the manufacture of carbon monoxide-hydrogen feed stocks suitable for a synthesis step wherein hydrocarbons and oxygen derivatives of hydrocarbons are produced. In another aspect this invention relates to the partial oxidation of a methane-containing gas. In still another aspect this invention relates to the production of synthesis gas by the partial combustion of methane or natural gas in a tangential flame furnace.

Carbon monoxide-hydrogen ymixtures have utility as feed stocks in Various synthesis processes. In a process of the Fischer-Tropsch type, carbon monoxide may be reacted with hydrogen in the presence of acatalyst to form hydrocarbons and oxygen derivatives of hydrocarbons. In a process of theoxo type, carbon monoxide and hydrogen add to olefin hydrocarbons, usually of high molecular weight, to form valdehydes and alcohols as the chief product. In a process for the manufacture of methanol, carbon monoxide and hydrogen react to produce methanol as a chief product. In a hydrogen manufacturing process, a hydrogen and carbon monoxide mixture may be contacted with steam in the presence of an iron catalyst to produce hydrogen and carbon dioxide, and the latter removed from the total product to produce hydrogen in high purity and yield. Such processes as the Fischer-Tropsch, oxo, and methanol synthesis are generally considered to comprise two steps, a synthesis gas preparation step and a synthesis step.

`In the first named step, carbon monoxide and hydrogen are prepared from raw carbon-containing materials such as hydrocarbons, coal, coke, or oil shale, by oxidation with an oxidizing gas "such as oxygen, steam or carbon dioxide, eitherY alone or in various combinations of such oxidizing agents. In some cases, various metal oxides may serve as oxidizing agents. Gas thus produced, i. e., the hydrogen-carbon monoxide product, is generally referred to as synthesis gas because it may be prepared in suitable yields and in a suitable mole ratio of hydrogen to carbon monoxide to render it valuable as feed gas for a synthesis step, such as above described; the term "synthesis gas employed hereinv refers to such a hydrogen-carbon monoxide mixture.

Hydrocarbon/gas can be partially oxidized to hydrogen and carbon monoxide by an oxidizing gas such as already mentioned, either catalytically or non-catalytically. The reaction employing carbon dioxide and/or steam is endothermic whereas the reaction employing oxygen is exothermic. The partial oxidation of a hydrocarbon to produce synthesis gas is illustrated by the following net equations, where methane representing the hydrocarbon, is oxidized by each of the oxidizing agents, oxygen, steam and oarbon dioxide:

This above equilibrium mixture shiftsV to the right or the left depending upon the prevailing temperatures subsequent to the partial oxidation reaction. For example at relatively low temperatures the equilibrium shifts to the hydrogen-l-carbon dioxide side, whereas at higher temperatures, the equilibrium shifts more completely in the opposite direction, provided a sufcient time is allowed Ato permit the mixture to come to equilibrium. The status of this equilibrium or water-gas shift as it is more commonly called, is important in the manufacture of synthesis gas, because unless optimum reaction temperatures are maintained and the reaction product rapidly quenched, relatively high yields of undesirable carbon dioxide are obtained.

The partial oxidation process generally comprises passing preheated oxygen and a hydrocarbon gas into a refractory lined partial oxidation or combustion chamber wherein the mixture is burned to form synthesis gas. Reaction temperatures are maintained preferably in excess of 2350 F. to obtain essentially complete hydrocarbon conversion to the desired equilibrium product mixture, and are controlled by the overall mole ratio of oxygen to hydrocarbon in the hydrocarbon-oxygen feed gas. In order to attain a temperature level in excess of 2350 F., and in order for the reaction to be sufficiently exothermic when oxidizing natural gas, for example, a mole ratio of oxygen to hydrocarbon, above 0.6:1 is usually required. Oxygen thus employed contributes to the formation of both carbon dioxide and water, with disproportionately high concentrations of water relative to carbon dioxide being produced; consequently the mole ratio of hydrogen to carbon monoxide in the synthesis gas product is usually below preferred values, which are in the range of about 1.7 l to about 23:1. In order to adjust the mole ratio of hydrogen to carbon monoxide in the synthesis gas product, either steam or carbon dioxide, or both, may be added to the hydrocarbon-oxygen feed. The reaction of each, steam and carbon dioxide, with methane is illustrated hereinabove. Steam, so added and reacted, contributes to an increased mole ratio of hydrogen to carbon monoxide in the synthesis gas product, and carbon dioxide so added and reacted, contributes to a decreased mole ratio of hydrogen to carbon monoxide therein. 'Ihese reactions are highly endothermic and the concentration in the influent hydrocarbon-oxygen mixture to the partial oxidation zone, of supplementary-steam and/or carbon dioxide to be so reacted, is necessarily limited in order that the partial oxidation reaction be maintained sufciently exothermic.

Utility of carbon monoxide-hydrogen mixtures as feed stocks for various syntheses has already been discussed. However, synthesis gas has been more generally utilized in the past as feed stock for a synthesis step of a process of the Fischer- Tropsch type wherein hydrocarbons and oxygen derivatives of hydrocarbons are produced in the presence of a catalyst. In carrying out a process of the Fischer-Tropsch type, carbon monoxide and hydrogen are usually introduced into the reaction zone in a mole ratio of hydrogen to carbon monoxide within the limits of 1.7:1 to 23:1, often about 2:1. Temperature, pressure and space velocity conditions are selected in accordance with the nature of the type product sought and the catalyst conditions employed. Catalysts used in the Fischer-Tropsch synthesis include cobalt, iron, nickel, and ruthenium, and these may be employed alone or they may be promoted with various promoters, particularly oxides of alkali metals, or alkaline earth metals, thoria or various other known metal oxides. When employing a cobalt-containing catalyst, temperatures within the range of 360 to 430 F. may be used, whereas nickel-containing catalysts are most generally employed within a temperature range of 340 to 400 F. and iron catalysts are more generally employed at temperatures in a range of from 430 to 650 F., dependent upon the type iron catalyst employed and upon whether fluidized or fixed bed operation is utilized. Space velocities are selected primarily with respect to the form of catalyst body employed, that is, a xed catalyst bed, or a fluidized catalyst bed or the like. When utilizing a fixed catalyst bed, space velocities may often be as low as 50 to 100 standard gas volumes of total reactants per catalyst volume per hours, whereas when operating with a fiuidized catalyst bed, space velocities within `the range of 1000 to 4000 standard gas volumes of total reactants per catalyst volume per hour are most generally employed. A preferred range of pressures suitable for hydrogenation is'v from about 5 to 15 atmospheres although .pressures up to 150 atmospheres, or even higher, may be used. Fluidized catalyst bed operation, usually employing a mesh size catalyst within the limits of -400, is most generally employed in a process of the Fischer- Tropsch type for a number of reasons, most important of which are the high space-time yields obtained and the ease in which the exothermic heat of reaction is removed.

This invention is concerned with the manufacture of carbon monoxide-hydrogen mixtures, and particularly those having utility as feed stocks for various syntheses, particularly the Fischer-Tropsch synthesis above discussed.

An object of this invention is to provide a process for the manufacture of a carbon monoxide-hydrogen mixture.

Another object is to provide a process for the manufacture of hydrocarbons and oxygen derivatives of hydrocarbons.

Another object is to provide a process for the manufacture of synthesis gas.

It is yet another object to provide a process wherein a hydrocarbon is partially oxidized to form carbon monoxide-hydrogen feed stock suitable for use in the synthesis step of a processfof the Fischer-Tropsch type.

Other objects will be apparent, to one skilled in the art, in View of the accompanying discussion and disclosure.

In accordance with this invention, carbon monoxide-hydrogen mixtures, particularly synthesis gas stocks for a process of the Fischer- Tropsch type, are manufactured from an oxygen-containing gas and a hydrocarbon gas, usually a natural gas rich in methane, in a tangential burner reactor. A portion of a methane-containing gas stock is burned with an oxygen reactant gas in such proportions that a steady flame is obtained in a tangential burner; resulting hot combustion gas, containing some hydrogen and carbon monoxide, described more fully hereafter, is then contacted with the remainder of the methane gas stock axially fed, alone or with some oxygen, into Athe reactor and reacted therewith to form more hydrogen and carbon monoxide at a selected temperature level maintained by heat liberated from burning the tangentially introduced feed.

In the practice of this invention, synthesis gas is prepared in a tangential burner reactor, or furnace system, containing two cylindrical sections, one of which may be termed a combustion section and the other a reaction section. These two sections are adjacent each other and coaxial, and are preferably disposed horizontally. The combustion section is positioned up stream from the reaction chamber, and has a shorter length, and preferably a larger diameter, as compared to that of the adjacently disposed reaction section. Broadly, a preferred embodiment of the process of my invention, comprises passingpart of a methane feed stock into the combustion sec'- tion in a direction tangent to its cylindrical side Wall, and at the same time axially introducing the remainder of the methane feed either alone, or with any additionally required oxygen, into the combustion section. The tangentially introduced methane is burned and the resulting hot total product mixture from the burning, referred to herein as combustion gas, comes into-contact with methane axially introduced, particularly in the reaction section. The term combustion gas as used herein, refers to total product from burning, which may contain in addition to products formed by combustion, any unreacted or unburned hydrocarbon and/or any inert constituits initially in admixture with the hydrocarbon or with the oxygen. For example, when burning methane with oxygen, combustion gas from that burning is considered herein to contain Vnot only products of combustion such as carbon dioxide, steam, hydrogen o-r carbon monoxide, but also any'unreacted hydrocarbon. When natural gas is burned, combustion gas thus formed may include nitrogen, in addition to those otherpossible components already named. The presence or absence, in the combustion-gas of any of these components above named, depends upon the selected burning conditions. When tangentially introduced methane feed contains sufcient oxygen -to completely burn methane, no carbon monoxide or hydrogen is formed. However, oxygenis preferably present in a mole ratio to methane, in a tangentially introduced feed stream, below that required for complete combustion of that methane, and consequently combustion gas more often contains carbon monoxide, hydrogen, carbon dioxide, and steam together with any unreacted methane and any inert diluents initially present in the hydrocarbon mixture. The tangentially added mixture is injected into the combustion section at suiiciently high velocity to cause combustion gas formed therein to flow spirally inward in the combustion section and substantially helically through the reaction section. Combustion gas thus formed, and methane axially introduced, pass together into the reaction section in a state of annular separation.

Operating in this manner, oxidation products in the combustion gas, other than carbon monoxide and hydrogen, may react with any remaining unburned tangentially added methane and with axially added methane, at a temperature level determined by regulating the burning'of the tangentially'introduced feed stock, while oxygen, added axially, with methane may react therewith and/or with any remaining unburned methane tangentially introduced. Preferably, in order to attain the maximum desired temperature in the reaction system, both the axial and tangential feeds are preheated, although it is Within the scope of my invention to'preheat one or the other, or neither. Preferably'the tangential feed contains less than suicient oxygen for its complete combustion and the axial feed contains the remainder of the 4oxygen reactant. Burning within the combustion chamber is regulated by adjusting the mole ratio of oxygen to methane introduced, and by adjustingthe quantity of tangential feed burned. The partial oxidation reaction takes place in both the vcombustion and reaction sections, and is conduct-ed in the tangential burner reactor system under controlled conditions'of temperature, oxygen to feed stock overall mole ratio, and contact time, to produce synthesis gas containing hydrogen and carbon monoxide in a desired hydrogen to carbon monoxide ratio within a wide range.

The accompanying diagrammatic drawing illustrates a preferred form of tangential burner reactor apparatus that may be employed in the practice of my invention. However, it is to be understood that various modifications of the illustrated process and apparatus may be made and still remainrwithin the scope of my invention. Figure 1 includes a transverse sectional View of a furnace embodying my invention, and 1 6 mentLof' this invention. VFigure 2 is a lcmgitudia nal sectional vview 'of the same furnace taken on the line 2-2 of Figure l. i f

' Referring to Figure 1, elongated reaction section I0 is lined with highly refractory material Il suchA as corundum brick, silica brick, mullite brick,-zirconia brick, sillimanite brick, or other similarv suitable materials resistant to high temperatures developed therein. Up stream from and adjacent to section I0 is combustion section I2, coaxial with section IIJ.A Section I2 is also lined'with lining material II already described. Lined sections I0 and I2 are surrounded by a layer of insulating material I3 and the whole is v 'contained in an outer steel shell I4. Combustion chamber I2 has a relatively large diameter in comparison -to its length While the reverse is true of reaction section I0. In a lower portion ofsection I 0 is an orifice choke I6.

In the upstream or inlet end of combustion zone I2, is feed inlet conduit 2| arranged axially so that feed introduced therethrough will pass axially through both sections I2 and IG. Surrounding feed conduit 2I is a coaxial, larger conduit, or oxygen inlet 22. The arrangement of conduits 2| and 22 defines an annular space through which oxygen may be axially passed into chamber I2. Oxygen when passed through that annular space serves to cool the inner end of conduit 2i; if any carbon deposits thereon,

oxygen thus introduced will support combustion to burn the carbon free. Diluted oxygen, steam, air, or amixture thereof may also be introduced through this annulus. Referringv to Figure 2, in combustion zone I2 are arranged inlets 23 which are so disposed that gas may be passed therethrough and into combustion zone I2 in a direction tangential to its cylindrical wall. Each tangential gas inlet 23 lmay consist of a small conduit 24 joining a larger conduit or tunnel 26, which latter terminates as an opening into chamber I2. An inlet pipe 21 extends part way into conduit 24. As mentioned hereinbefore, the tangential gas inlet assembly is so arranged that gas entering chamber I2 therethrough does so in a direction tangent to the cylindrical wall at its point' of inlet. Most of the tangentially introduced gasis burned within tunnels 2G.

Cooling assembly I8 down stream from reaction section I and adjacent thereto consists. of water jacket 28, water spray 29, Water inlet conduit 3l to jacket 28, space 32 in which cooling water is passed through jacket 28, water outlet 33 froml jacket 28, and water inlet 34 to sprayer nozzle 25.

In a preferred operation of the process of my invention a combustion mixture of methane and oxygen is preheated and charged to tangential burners v23. This may be done by introducing methane fro-m line 4I through line 43 in admixture with oxygen introduced from line 41 through line 4,8, into preheater 42 wherein the resulting methane-oxygen admixture is preheated to the desired temperature. Preheated methane-oxygen is withdrawn from preheater 42 through line 5I and introduced tangentially into combustion chamber I2 through lines 52 and 21. If it is desired to dispense with all preheating, methane from line 4I and oxygen from line 41 may be respectively introduced to line 21 from line :44 and from lines 49 and 52. In some instances it may be advantageous to preheat a selected portion of either or of both the methane and oxygen and to introduce the preheated gas into line 21 together with oxygen and/or 7 'methane by-passing preheater 42 jv through. lines 49 and lll respectively. Tangentially introduced gas is burned in tunnels 2 5, Vthe combustion gases thus produced traveling spirally toward the center within combustion zone I2 and then traveling" helically throughoutj the uelongated section as a'blanke't along the wall. The Ym'ole ratio offoxygen to methane inthe 'total tangential feed is greater than the overall mole ratio ofroxygen to methanel introducedfinto the reaction system, and is preferably jless Vthan that required for complete combustion of `themethane'introduced therewith. The remainder Aof themet-hane and any remainingrequired oxygen are each preheated and introduced axially into combustion chamber I2. This may be done by preheating methane introduced from line 56, in preheater l and passing the resulting preheated gas through' lines 58, 59 and 2l, a-xially into the reaction system. If it is desired to dispense-with methane preheating, methane from line- 54 may be introduced into'lines 59 and 2|. If desired, preheated gas from line 58V may-be admixed in line 59' withl methane from line 54 in any desired proportion. When introducing oxygen into the reaction systemv axially, oxygen from line 6i isv preheated in preheater 62, and the resulting preheated oxygen is passed through lines 63 and 6E into combustion chamber I2, through an annular space provided by pipes 22 and 2l described hereinbefore. Oxygen from line- 64 may be admixed in line 66 with preheated oxygen from line 63 when desired. However, if desired, preheating of oxygen in preheater 62 may be dispensed with, in. which case oxygen from line 6dV would be the sole source of oxygen in line 66. In many instances, it may be-desirable to charge a mixture of oxygen and methane through axial pipe 2|-, the feed in this case to vline 5 or 54- being that mixture, the feed point chosen according to whether or'not preheating is desired. Better results are usually obtained when a portion ofthe oxygen is premixed with the axial feed. The mole ratio of oxygen to-methane in the Ytotal axially in-` troducedy feed is less than-the overall mole ratio of oxygen to methane introduced-into' thereaction system. The'volu-me ratio-ofv total axially introduced hydrocarbon gas to total tangentially introduced hydrocarbon gasis withinthe limits of 0.3:1 to 3:1, and preferably Within.the limits of 1.5:1-to 3:1.

The amount of preheat for all reactants herein isY limitedin the Vcas-e of an oxygen stream by its reactivity, and in the case of an oxygenmethane mixture, by the tendancy ofthat mixture to preignite. For that reason itV is usually desirable to limit the preheat on anyrof the oxygen-containing feed streams di'scussed'h'erein to a temperature usually not greater' than about 1000 F. When preheating hydrocarbon, alone, preheat temperatures Within the range of 80G-1200" F. may beadvantageously employed.

When it is `desired to adjust the mole ratio of hydrogen to carbon monoxide'in the nal synthesis gas product by supplementing theY methane feed with steamer carbon dioxide, the supplementary gas, i. e., steam,V and/or carbon'fdioxide, may be introduced into the reaction system, axially, tangentially, or both. Supplementary gas from line 68 may be passed through line 'il directly to-coinbustion section l2 through lines 59 and 2l, or itmay be passedv through lines 65 and 55, to preheater 5l, preheated Stherein, andthenpassed through lines 5l, 52- and 21 into combustion-section l2. If desired, selected 8 portions of supplementary ygas may be/preheated and admixed with unheated supplementary gas in line- 5&3.` Similarly, supplementary gas from line G'Iqmay be passedto' combustion section l2 through lines-44 andv 21, orv itY may be passed through line 43-to preheater'42, preheated therein and `then'passedthroughjlines 5|-, 52 and 21 into combustion section l2. If desired, selected Vportions of supplementary gas'rnay bepreheated and admixed with unheated' supplementary `gas inline V2".V 'Ihelmaximum amount ofi supplementary gas added, in'any'case; is limited to that amount which can' be utilized While still Vmaintaining the`overall partial oxidation sufliciently exothermic, i. -e., so-that the overall partial oxidation reaction is not endothermic. VAlthough supplementary steam-and/or carbon dioxide gas may be introduced axially, tangentially, or both, I prefer the former, i.v e., its axial. addition.- A specicmanner inrwhich steamand/or carbon dioin'de I,may be `added together with a gaseous hydrocarbon to al cylindrical partial oxidation chamber, as an endothemically reacting protective gasmixture for theA chamber Wall, in a process for the manufacture of synthesisv gas, is disclosed in the copending. application of J. S. Cromeans, 'Serial-No. 84,124, led March-29, 1949.

The burning takingplace in-tunnels -26 serves as the sou-rceof heat for the partial oxidation taking place in the system, and is regulated by adjusting thev amount of tangential feed and-the mole ratio of oxygen to-methane-therein. Sufficient heat is provided to effect-.the partial oxidation at a temperature Within the range ofv 2000 to` 2500UYF., preferably from 2400 to 2500 F. Combustion products ofv the burning in tunnels 26 comprise carbon dioxide, hydrogen, steam, and carbonmonoxide in relative amounts dependent largely upon themole -ratio ofoxygen to methane in the tangential feed.

TheY wallsof the reaction section being blanketed by combustion .gas provides the advantage that` the low oxygen contentV axial streamv does not contact the Walls Yuntil reaching the latter portion of the reactor,.and thus little chanceis afforded Vthehydrocarbons to contact *thev hot wallsand .decompose withv the formationof. undesirable carbonaceous deposits. Y

In .order to establish a most favorable equilibrium-inthe netA reaction product, itis necessary that all carbonV dioxide and steamtherein are substantially completely reacted with any unreacted methane` present. In. orderl to .promote equilibrium in the total product gas of the reactor, I prefer to employ a-mixing orice or choke I6, in elongated section l0, in order to facilitate the mixing of the central .stream and the helical blanket. This orifice or choke isV so positioned that mixing iseffe'cted following the portion of section l0 inV which rapid initial reaction takes place; This willinsure'complete contact of steam and carbon dioxide inthe wall blanket with unconverted methane in the central portion and will thus promote further reaction and attainment of more 'complete equilibrium.

When-desired, the hot reactionmixture may be freedV ofv any suspended carbon and then passed over amop-up catalyst such as nickel, cobalt, or iron, in order to acceleratethe reaction. of any remaining steam and carbon dioxide with unconverted methane. geous. when the gas mixtureY containsV unreacted methane andlhaslcooled'to a temperature as 10W as 20.00. F: orless', since the equilibrium provided inthe presence Vofl such a1catalyst is favorable, at temperatures as low` as 1500 F.' Operating in This isespecially advantathis manner, the rate of reaction between any remaining carbon dioxide and/or steam, with any unreacted methane is suiiiciently high to permit utilizing the sensible heat of the gas in those endothermic reactions until the gas temperature is as low as 1500 F., thus permitting the greater heat efciency in the operation of the process. However, at reaction temperatures of from 2400 F. to 2500 F., the water-gas equilibrum is shifted so that very little carbon dioxide remains in the product gas, and the use of a catalyst is not particularly advantageous, provided the product gas is rapidly quenched to a temperature somewhat below 1200 F., such as from 800 F. to 1000 F. When operating in this manner, product gas from section Il! is passed into cooling assembly I8 described hereinabove and rapidly quenched to a temperature below 1200 F., in both indirect and direct heat exchange relation with water. Product gas from cooling assembly 28 is then conducted through line I9 to purification zone 36 wherein any entrained carbon or tarry materials, formed in zones l2 and/or l0, are removed. Carbonaceous materials entrained in gas product entering zone 36 and separated in zone 36 may be withdrawn through line 31. Steam present in the gas entering zone 36 is removed therein preferably by condensation and withdrawn as Water through line 35. Purified synthesis gas is passed from zone 36 through line 38 to a Fischer-Tropsch synthesis step 39 wherein the hydrogen and carbon monoxide .are reacted in the presence of a catalyst as described hereinbefore, to form hydrocarbons and oxygen derivatives of hydrocarbons. Total effluent from zone 39 is passed through line 10 to product separation means 12 comprising coolers, storage tanks. fractionation equipment and the like, not individually illustrated, and which are ordinarily employed in the separation of product fractions contained in the eiulent' to a Fischer-Tropsch synthesis. Tail gas comprising carbon dioxide, hydrogen and some carbon monoxide is withdrawn from zone 'I2 through lines 13 and 14 or may be recycled through lines 13 and 16 to the Fischer-Tropsch synthesis. Other selected fractions withdrawn from zone I2 may be a normally gaseous hydrocarbon fraction through line TI, a gasoline fraction through line 18, a gas-oil fraction through line 19, a heavy wax and wax-like product fraction through line 8 I and by-product Water through line 82.

For convenience and clarity certain apparatus, such as pumps, surge tanks, accumulatore, valves, etc. have not been shown in the drawing. Obviously such modifications of the present invention may be practiced Without departing from the scope of the invention. l

In the preferred embodiment above described, the overall oxygen to methane mole ratio is somewhat above the theoretical of 0.5:1 as indicated by Equation 1 hereinabove, about 0.52:1 to 0.85:1 being a suitable range; when air is the oxidizing gas the air-methane overall volume ratio is preferably within the limits of 2.60:1 to 4.25z1. When charging methane stocks containing other suitable hydrocarbons higher overall oxygen to natural gas mole ratios are employed, e. g., when charging natural gas, usually containing from ZO-85 per cent methane, a mole stoichiometric ratio of oxygen to natural gas within the limits of 0.6:1 to 0.9:1 is advantageously employed; when air is the oxidizing gas the preferred mole ratio of air to natural gas is preferably within the limits of 3.0:1 to 4.5:1.

Though. methane alone may be fed axially, more efficient conversions are obtained whena portion of the oxygen is added axially.

Reaction pressure is usually about atmospheric, although elevated pressures may be employed when desired.

The ratio of length to diameter of reaction section I0 may be varied, but for any given diameter, the length should be sucient to provide a contact time sufficient for complete reaction such as, for example from about 0.05 to about 5 seconds and preferably less than about 0.5. The ratio of the diameter of the enlarged combustion zone to the diameter of theelongated reaction section may be varied, although a ratio between the limits of 1.5:1 to about 4 1 is preferred. It is within the scope of this invention to utilize an unenlarged combustion section. When so operating it may often be advantageous to employ a greater number of tangential burners to blanket the reactor walls.

In thepartial oxidation of hydrocarbon stocks to produce hydrogen-carbon monoxide mixtures suitable for use as snythesis gas in a process of the Fischer-Tropsch type, oxygen of at least to per cent purity is preferably employed. However, When desired, an oxygen-containing gas such as air or any suitable oxygen-enriched gaseous mixturemay be utilized, although the nal synthesis gas product is rich in nitrogen. and its utility as feed stock for a Fischer-Tropsch synthesis is less, not only from an economic standpoint, but also with respect tothe eect of the presence of such high concentrations of nitrogen on the ultimate yield of desired Fischer- Tropsch products. However, such nitrogen-containing product gases may be utilized as synthesis gas if. desired, or as a fuel gas, or for any purpose for which a 10W B. t. u.containing gas is needed, and the use of an oxygen-containing gas such as air or any other suitable oxygen-containing gas, is within the scope of my invention'.

Although in a preferred embodiment of my invention I produce hydrogen-carbon monoxide stocks suitable for use as synthesis gas in a process of the Fischer-Tropsch type, it is within the scope of my invention to alter conditions of my process to produce other types of hydrogencarbon monoxide-containing gases, havingutility in various applications other than as a Fischer- Tropsch synthesis feed stock; particularly as fuel gas. In the practice of this embodiment, overall mole ratio of oxygen to hydrocarbon feed, regulated operating temperature, and choice Aof hydrocarbon.. feed stock, are imported variables lending themselves to application within wider ranges of process conditions, than those lnecessarily adhered to in the practice of my preferred embodiment, i. e., in the manufacturecf synthesis gas.

Advantagesof this invention are illustrated by the following examples.r 'Ihe'reactantsand their proportions, and other specific ingredients are presented as being typical andshould not be construed to limit the invention unduly.

Example 1 Synthesis gas is formed in a tangential burner reactor having a 33 inch combustion section with two tangential burners. The axial length is 12 inches. The'reactionsection is coaxial with the combustion section and is l2 inches in diameter andll feet long. Air is used as the oxygen- 11 containinggas and. the .hydrocarbon feed .gas is natural gashaving :the following .composition Component Mole. per cent Nitrogen 8.5 Methane 81.4 Ethane 5.8 Propane `3.1 lButane. 0.9

Pentanes and heavier 0.03

Process conditions and synthesis gas product obtained are summarized in the followingv table.

oxygen .at a velocity described hereafter, into a rst cylindrical Zone having a diameter. greater than its length', in. va direction tangentv to the OPERATING DATA AND RESULTS `ChzsEeed, CFE Tan Tang. Air-Gas Axial Effluent Analysis Percent Y v Airg lfeed, Volume Feed by Volume Unszm Comb. 'Run No. Rate AAir-Gas Ratio, Gas t s Chamber Axial Tan- 'CFH VVolume Total Temp. i ma e Temp.F. gential Ratio Feed FF. CO2 CO Hz CH; N2

P-124-. 9,-000 3, 950V 50, 000 .l2 6 3. 86 1, 000 4.62 7. 95'v 17. 61 3. 25 65. 0 1.52 2, 840 P-125- 11, 150 4, 060 50,000 12. 3 3. 28 1, 000 6. 27 6. 34 16.91 4. 76 64. 14 1.58 2, 635 P-126 6, 000 7, 100 50, 000 7. 1 3. 8 1', 000 4. 71 8. 98 15; 48l 5. 85 63. 53 1. 45 2, 705 P-127-- 8,000 7, 100. 50, 000 7.1 3. 33 1, 000 4. 61 8. 45 15. 28 7. 85 62. 26 1`. 55 2,700' P-l28- 10, 100 7,100 50, 000 7. 1 2. 9 1, 000 4. 56 8.18 1.4. 38 .9. 37 61. 62v 1-89 2, 752 P-129 13,A 200 7, 100 50, 000 7. 1 2. 46 1,000 4.12 7. 8O 13. 77 11. 54' 59. 52 2. 27 2, 770 P-102 1 8, 000 3, 970 50, 000 12. 5 4. 5 l 1, 000 4. 52 9'. 32 16.108 2. 43V 2, 800 P-101-2 8, 000 3, 970 50, 000 12. 5 4. 35 1, 000 4. 44 9.24 16. 46 2. 32 2, 783 P-105-. 6, 240' 7,V 100 50, 000 7. 1 3.8 60 4. 67 9. 58 13'. 40 6. 22 2, 691

14,000 CFH air mixed with axial gas feed.

2.2,000 CFH air mixedl with axial gas feed.

Runs P105 and P-126 are nearly identical with theexceptionof the axial feed temperature. ABy material balance. the preheated axial. .feed run showssubstantiallyno carbonformation, whereas the .unpreheated feed shows carbon produced. The. comparison of these two examples illustratesthe advantage .of preheating, atleast the axial feed.

YA comparison of runs P-124 and.P-l26 each having been conducted approximately under the same total feed and reaction conditions, shows that undesirable carbon formation'takeswplace when the tangential burner feed contains Vmore than a theoretical quantity'of oxygen for completely burning vthe tangentially introduced hydrocarbon, Whereas substantially norcarbon is formed when the tangential burner feed contains a greater amount of hydrocarbon and the axial feed less.

A'comparison'of runs P-l01 and P-10'2- shows the eii'ect ofA change in oxygen content of'the axial feed. Undesirable formation of carbon increases With decreasing oxygen content of the axial feed. I

Example 2 Synthesis gasis formed inaccordance with the process of Example 1,r in a .tangential burner reactor ot the type described in .Example 1,.eX- cept .that commercialgrade oxygen is used in the place .of air, and methane is charged instead of natural gas. Methane is charged axiallyfat the rate o'fA 6000 c. f. h. and tangentially at'the rate of 7,100 c. f. h. Oxygen is introduced tangentially at the rate lof 10,000 c. f. h., the oxygen to methane mole ratioin the tangential feed being 1.4:1, and the overall oxygenV to methane rmole ratio being 076:1. Axiallyl introduced feed is preheated to 1000 F.V Gaseous efuent from the burner reactor has a composition as follows:

Component: Mole per cent Carbon dioxide 12.9 Carbonvmonoxide 24.5 Hydrogen 42.6 Methane 16.0 Unsaturates 4.0

Total 100.0

innersidewall ofV said first cylindricalA zona-,and in a Amole-ratio of oxygen to natural gas `higher than-an overall oxygentonatural gas mole ratio described hereafter and lower than that required for completely burningv the tangentially introduced natural` gas burning said tangentially introduced natural vgas insaid rst cylindrical zone, .and regulating said burning as, described hereafter; passing combustion gas formedfrom saidburning, fromA saidrst. cylindrical zone ,into and through a second cylindrical. zone longerv than. coaxial. with, andadjacent said rst cylindrical zone, and havingadiameter smaller than that of said rst cylindrical Zone; regulating said burning to produce heat tor maintaina temperature through said rstfand second cylindrical zones within the limits'M2000- 250W7 F.; maintaining said velocity of tangentially injected natural gas and oxygen sufficiently high that said combustion gas follows an inward spiral path in saidcrst cylindrical'zone .and a helical" path through said second cylindrical zone adjacent' the inner wall of at least an yinitial portion thereof; passing oxygen and natural gas axially into said rst cylindricalzone in ya mole ratio of oxygen .to natural gas lower than :said overall moleY ratio, and .through said .second cylindrical zone.. whereby axially .introduced gas passes longitudinally through .said-.rst .cylindrical zone and then into saidsecond cylindrical .zone in an initialstate of annularseparation from. helically owing gases; maintaining-a mole ratioof total axially and tangentially introduced oxygen to total axially and tangentially-introduced .natural gas within the limits of 0.6:1 to 0.9:1 as -sai'd overall mole ratio described above; maintaining the lvolume of totalaxially introduced hydrocarbon to total tangentiallyy introduced hydrocarbon within the limits of 1.511 to 3:1;A withdrawing-efuent from said second cylindrical zone andY quickly quenching same to a temperature below 1000 F.; and recovering from the-quenched effluentaghydrogen-carbonmonoxide-gas mixture suitablefor use as synthesisv gas in a. processofthe Fischer-,Tropsch type. U Y

2; 'I'he process of claim 1 wherein axially introduced reactants are'preheated to' a temperature not exceeding 1000 F.

3. The process of claim 1 wherein tangentially introduced feed is preheated to a temperature not exceeding 1000 F.

4. The process of claim 1 wherein natural gas to be added tangentially is preheated and admixed with unpreheated oxygen and the resulting admixture is introduced into said first zone at a temperature not higher than 1000 F.

5. The process of claim 1 wherein natural gas to be introduced axially is preheated to a temperature in the range of 800 to 1200 F.

6. The process of claim 1 wherein supplementary steam is axially introduced into said first zone to adjust the mole ratio of hydrogen to carbon monoxide in the synthesis gas product, in an amount not exceeding that which can be utilized while still maintaining the overall partial oxidation autothermic.

7. The process of claim 1 wherein the flow of gases through a downstream portion of said second cylindrical zone is partially obstructed to facilitate mixing of any remaining unreacted oxidizing gas with any unreacted hydrocarbon to promote further reaction to form carbon monoxide and hydrogen.

8. A process for producing a hydrogen-carbon monoxide gas mixture suitable for use as synthesis gas in a process of the Fischer-Tropsch type, comprising injecting a mixture of natural gas and air at a velocity described hereafter, into a first cylindrical zone having a diameter greater than its length, in a direction tangent to the inner side wall of said first cylindrical zone, and in a volume ratio of air to natural gas higher than an overall air to natural gas volume ratio described hereafter and lower than that required for completely burning the tangentially introduced natural gas; burning said tangentially introduced natural gas in said first cylindrical zone,

and regulating said burning as described hereafter; passing combustion gas formed from such burning, from said first cylindrical zone into and through a second cylindrical zone longer than, coaxial with, adjacent said first cylindrical zone, and having a diameter smaller than that of said first cylindrical zone; regulating said burning to produce heat to maintain a temperature through said first and second cylindrical zones within the limits of 2000-2500 F.; maintaining said velocity of tangentially injected natural gas and air sufficiently high that said combustion gas follows an inward spiral path in said first cylindrical zone and a helical path through said second cylindrical zone adjacent the inner wall of at least an initial portion thereof; passing air and natural gas axially into said first cylindrical zone in a volume ratio of air to natural gas lower than said overall volume ratio, and through said second cylindrical zone, whereby axially introduced gas passes longitudinally through said first cylindrical zone and into said second cylindrical zone in an initial state of annular separation from helically flowing gases; maintaining a volume ratio of total axially and tangentially introduced air to total axially and tangentially introduced natural gas within the limits of 3.0:1 to 4.5:1 as said overall mol ratio described above; maintaining the Volume ratio of total axially introduced hydrocarbon to total tangentially introduced hydrocarbon within the limits of 1.5:1 to 3:1; withdrawing eiiiuent from said second cylindrical zone and quickly quenching same to a temperature below 100i)c F.; and recovering from quenched effluent a hydrogen-carbon monoxide gas mixture suitable for use as synthesis'gas in a process of the Fischer-Tropsch typ'e.' v

9; A process for Aproducing a hydrogen-carbon monoxide'gas mixture suitable for use as synthesisl gas in a process of the Fischer-Tropsch type, comprising injecting a mixture of methane and air at a velocity described hereafter, yinto a first cylindrical Zone having a diameter greater than its length, in a direction tangent to'the inner side wallof said first cylindrical zone, and in a Volume ratio of air to methane higher than an overall air to methane volume ratio described hereafter and lower than that required for completely burning the tangentially introduced methane;` burning said tangentially introduced methane in said first cylindrical Zone, and regulating said burning as described hereafter;

vpassing combustion gas formed from said burning, from said first cylindrical Zone into and through a second cylindrical zone,=longer than, coaxial with, adjacent said first cylindrical zone, and having a diameter smaller than that of said first cylindrical zone; regulating said burning to produce heat to maintain a temperature through said first and second cylindrical zones within the limits of 2000-2500 F.; maintaining said velocity of tangentially injected methane and air sufficiently high that said combustion gas follows an inward spiral path from said first cylindrical zone and a helical path through said second cylindricalzone adjacent the inner wall of at least an initial portion thereof; passing air and methane axially into said first cylindrical zone in a volume ratio of air to methane lower than said overall volume ratio, and through said second cylindrical zone, where by axially introduced gas passes longitudinally through said first cylindrical zone and into said second cylindrical zone in an initial state of annular separation from helically flowing gasesj maintaining a Volume ratio of total axially and tangentially introduced air to total axially and tangentially introduced methane within the limits of 2.60:1 to 4.2521, as said overall volume ratio described above; maintaining the volume ratio of total axially introduced methane to total tangentially introduced methane Within the limits of 1.5:1 to 3:1; withdrawing eiiiuent from said second cylindrical zone and quickly quenching same to a temperature below 1000 F.; and recovering from the quenched eliiuent a hydrogen-carbon monoxide gas mixture suitable for use as synthesis gas in a process of the Fischer-Tropsch type.

10. A process for producing a hydrogen-carbon monoxide gas mixture suitable for use'as synthesis gas in a process of the Fischer-Tropsch type, comprising injecting a mixture of methane and oxygen at a Velocity described hereafter, into a first cylindrical zone having a diameter greater than its length, in a direction tangent to the inner side wall of said first cylindrical zone, and in a volume ratio of oxygen to methane higher than an overall oxygen to methane volume ratio described hereafter and lower than that required for completely burning the tangentially introduced methane; burning said tangentially introduced methane in said first cylindrical zone, and regulating said burning as described hereafter; passing combustion gas formed from such burning, from said first cylindrical Zone into and through a second cylindrical Zone, longer than, coaxial with, adjacent said first cylindrical zone, and having a diameter smaller than that of said first cylindrical zone; regulating said burning to produce heat to maintainV a temperature through said-first and second cylindrical zones within the limits of 2000-2500 F.; maintaining said velocity of tangentially injected methane and oxygen sufciently vhigh that said combustion gas follows an inward spiral path in said rst cylindrical zone and a helical path through said second cylindricalzone adjacent the inner wall of at leastk an initial portion thereof; passing oxygen andmethane .axially into sai'd first' cylindrical zone in a Volume ratio of oxygen to methane lower than said overall Volume ratio, and through said second cylindrical zone, whereby axially introduced gas passes longitudinally through said first cylindrical zone-and then into said second cylindrical zonein an initial state'of annular separation from helically flowing gases; maintaining a volume ratio of total axially vand tangentially introduced oxygen to total axially and tangentially introduce methane within the limits of 052:1 to 0.85z1, as'said overall volume ratio described above; maintaining the volume ratio of total axially introduced methane to total tangentially'introducedmethane within the limits of 1.6 1.511 to 3:1; withdrawingefiluent from said second cylindrical zone and quickly quenching same to a temperature below 1000 F.; and recovering from the quenched effluent a 'hydrogen-carbon monoxide gas mixture suitable for use as synthesis gas in a process of the Fischer-Tropsch type.

JOSEPH C. KREJCI.

REFERENCES CETED The following references are of record in the ile of this patent:

UNITED STATES 'PATENTS Number vName Date 2,051,363 Beekley Aug. 18,1936 2,106,137 Reed Jan. 18, 1938 2,347,682 Gunness May 2, 1944 2,368,828 Hanson et al Feb. 6, 1945 2,375,795 Krejci May V15, 1945 2,375,796 Krejci May A15, 1945 2,375,797 Krejci May 15, 1945 2,375,798 Krejci May 15, 1945 2,419,565 -Krejci Apr. 29, 1947 Clark Oct. 5, 1948 

1. A PROCESS FOR PRODUCING SYNTHESIS GAS, COMPRISING INJECTING A MIXTURE OF NATURAL GAS AND OXYGEN AT A VELOCITY DESCRIBED HEREAFTER, INTO A FIRST CYLINDRICAL ZONE HAVING A DIAMETER GREATER THAN ITS LENGTH, IN A DIRECTION TANGENT TO THE INNER SIDE WALL OF SAID FIRST CYLINDRICAL ZONE, AND IN A MOLE RATIO OF OXYGEN TO NATURAL GAG HIGHER THAN AN OVERALL OXYGEN TO NATURAL GAS MOLE RATIO DESCRIBED HEREAFTER AND LOWER THAN THAT REQUIRED FOR COMPLETELY BURNING THE TANGENTIALLY INTRODUCED NATURAL GAS; BURNING SAID TANGENTIALLY INTRODUCED NATURAL GAS IN SAID FIRST CYLINDRICAL ZONE, AND REGULATING SAID BURNING AS DESCRIBED HEREAFTER; PASSING COMBUSTION GAS FORMED FROM SAID BURNING, FROM SAID FIRST CYLINDRICAL ZONE INTO AND THROUGH A SECOND CYLINDRICAL ZONE IONGER THAN, COAXIAL WITH, AND ADJACENT SIAD FIRST CYLINDRICAL ZONE, AND HAVING A DIAMETER SMALLER THAN THAT OF SAID FIRST CYLINDRICAL ZONE; REGULATING SIAD BURNING TO PRODUCE HEAT TO MAINTAIN A TEMPERATURE THROUGH SAID FIRST AND SECOND CYLINDRICAL ZONES WITHIN THE LIMITS OF 2000-2500* F.; MAINTAINING SAID VELOCITY OF TANGENTIALLY INJECTED NATURAL GAS AND OXYGEN SUFFICIENTLY HIGH THAT SAID COMBUSTION GAS FOLLOWS AN INWARD SPIRAL PATH IN SAID FIRST CYLINDRICAL ZONE AND A HELICAL PATH THROUGH SAID SECOND CYLINDRICAL ZONE ADJACENT THE INNER WALL OF AT LEAST AN INITIAL PORTION THEREOF; PASSING OXYGEN AND NATURAL GAS AXIALLY INTO SAID FIRST CYLINDRICAL ZONE IN A MOLE RATIO OF OXYGEN TO NATURAL GAS LOWER THAN SAID OVERALL MOLE RATIO, AND THROUGH SAID SECOND CYLINDRICAL 